Operation CHARM: Car repair manuals for everyone.
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Engine Table

Cylinder bore diameter (after honing) For piston grade F 90.990 - 90.998 mm
For piston grade G 90.999 - 91.007 mm
For piston grade H 91.008 - 91.016 mm
+0.020 in. 91.513 - 91.526 mm
Piston, skirt clearance - 0.01 - 0.026 mm
Piston diameter For piston grade F 90.972 - 90.980 mm
For piston grade G 90.980 - 90.989 mm
For piston grade H 91.990 - 91.998 mm
+0.020 in. 91.480 - 91.506 mm
Piston ring, gap when fitted in bore Top compression ring 0.40 - 0.65 mm
Second compression ring 0.40 - 0.65 mm
Oil control ring 0.30 - 0.55 mm
Piston pin Length 77.12 - 77.25 mm
Outside diameter 23.807 - 23.812 mm
Inside diameter 14.30 - 14.81 mm
Crankshaft Journal diameter, P (pink) 76.210 - 76.220 mm
Journal diameter, W (white) 76.220 - 76.230 mm
Journal diameter, G (green) 76.230 - 76.240 mm
Thrust washer thickness - 2.57 - 2.62 mm
Permissible end float - 0.10 - 0.28 mm
Diametrical clearance - 0.016 - 0.055 mm
Crankpin diameter R (red) 52.970 - 52.980 mm
Y (yellow) 52.980 - 52.990 mm
B (blue) 52.990 - 53.000 mm
Main bearing cap 136 - 142 Nm SPS
SPS System (+90 degrees and non-reuseability). Discard fixings on removal and replace with new bolts / nuts every time a 'strip down' is carried out. Refer to Engine, Service and Repair, Service Procedures, SPS Joint Control System and Sealants.
Connecting rod Length between centers 166.320 - 166.420 mm
Bore for large end bearing 56.731 mm
Bearing diametrical clearance 0.023 - 0.059 mm
Bearing side clearance 0.132 - 0.233 mm
Bore for small end bushing 26.975 - 27.000 mm
Connecting rod nuts and bolts 52 - 55 Nm SPS
SPS System (+90 degrees and non-reuseability). Discard fixings on removal and replace with new bolts / nuts every time a 'strip down' is carried out. Refer to Engine, Service and Repair, Service Procedures, SPS Joint Control System and Sealants.
Crankshaft damper/pulley bolt 183 - 223